Exhaust housing

ABSTRACT

The disclosure relates to a gas-carrying exhaust gas housing of an internal combustion engine comprising: a manifold section, having a central axis and multiple manifold pipe connectors, for securing on a flange plate for connecting to a cylinder of an internal combustion engine; a catalyst housing section having a central axis; and an exhaust pipe connector section provided downstream of the catalyst housing section, for connecting to an onward-conveying exhaust system. In addition, together with catalyst housing section and exhaust pipe connector section, the manifold section forms a two-shell exhaust housing having a first half shell and a second half shell, wherein the two half shells have a separation plane (T) running parallel to the central axis at least in sections, wherein the manifold section has multiple integral manifold pipe connectors which can be attached directly to a flange plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No. PCT/EP2016/068774, filed on Aug. 5, 2016, and published in German as WO2017/25470 A1 on Feb. 16, 2017. This application claims the priority to German Patent Application No. 10 2015 113 137.4, filed on Aug. 10, 2015. The entire disclosures of the above applications are incorporated herein by reference.

FIELD

The disclosure relates to a gas-carrying exhaust gas housing of an internal combustion engine comprising: a manifold section, having a central axis and multiple manifold pipe connectors, for securing on a flange plate for connecting to a cylinder of an internal combustion engine; a catalyst housing section having a central axis; and an exhaust pipe connector section provided downstream of the catalyst housing section, for connecting to an onward-conveying exhaust system, wherein, together with catalyst housing section and exhaust pipe connector section, the manifold section forms a two-shell exhaust housing having a first half shell and a second half shell, wherein the two half shells have a separation plane running parallel to the central axis at least in sections, wherein the manifold section has multiple integral manifold pipe connectors which can be attached directly to a flange plate or a cylinder head.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

An air-gap insulated exhaust housing is already known from U.S. Pat. No. 6,555,070 B1. Said air-gap insulated exhaust housing has a multi-piece gas-carrying internal housing and a two-shell external housing or combination housing. The internal housing has a manifold section, a catalyst housing and an exhaust pipe connector, wherein the manifold section is attached via an inlet channel and the exhaust pipe connector is attached via an outlet channel to the catalyst housing. Five housing parts connected after one another are consequently provided in order to form the gas-carrying internal housing.

Both U.S. Pat. No. 5,419,125 A and U.S. Pat. No. 5,589,144 A describe a two-shell catalyst housing, at the front-side end of which formed parts for receiving angled manifold pipes are provided in the region of the respective shell edge. The manifold itself is formed from four angled manifold pipes which are connected at the end side with the catalyst housing, on the one hand, and with a flange plate, on the other hand.

A two-shell manifold housing having manifold pipes and a catalyst housing is known from WO 2015/040531 A1, wherein the manifold pipes and the catalyst housing are an integral part of the manifold housing.

SUMMARY

This section provides a general summary of the disclosure, and is not a com-prehensive disclosure of its full scope or all of its features.

The object of the disclosure is to configure and arrange a gas-carrying internal housing in such a manner that a simplified assembly is guaranteed.

The object is achieved according to the disclosure in that the respective manifold pipe connector is configured as a rim hole inside the first half shell.

As a result, the manifold section, the catalyst housing section and the exhaust pipe connector section are integral parts of the two-shell exhaust housing, and it is no longer necessary to assemble or connect multiple parts which are attached after one another in the direction of flow separately, but that is not all.

Rim holes can be welded better than formed parts inside the shell edge, since a gap and, thus, a break in the material, which adversely influences the welding process, is omitted between the housing halves.

The catalyst housing section, in particular the rim holes, can also be easily calibrated by processing the exhaust housing in a suitable manner. The exhaust housing can consequently be secured or welded with less outlay to a flange plate or a cylinder by means of the exhaust pipe connector section and the rim holes.

Deep-drawn components for exhaust system segments having such a complex construction require huge outlay during realization. Since the degree of forming plays a crucial role, single-piece deep-drawn components are actually out of the question for such segments. Therefore, multi-piece designs, which can also be found in the prior art, tend to fall within the framework of what is considered by the average person skilled in the art.

To this end, it can also be advantageous if the manifold section has a connection plane A for a flange plate, which is spanned by the manifold pipe connectors, wherein the manifold pipe connectors additionally span a connection plane K at the manifold section, and if the separation plane T is aligned parallel to the connection plane A and parallel to the connection plane K at least in the region of the manifold section. In contrast to the prior art, the separation plane T is aligned such that the manifold pipe connectors can be configured as rim holes. Accordingly, the separation plane T does not intersect the manifold pipe connectors or the respective manifold pipe connector.

It can additionally be advantageous if the respective manifold pipe connector is configured straight or free of bends or cylindrically and/or the manifold pipe connectors are configured identically in terms of their form and size. As already explained, deep-drawn components for exhaust system segments having such a complex construction require a huge outlay during realization. The afore-mentioned configuration of the manifold pipe connectors keeps this outlay in check.

It can furthermore be advantageous if the connection plane A is aligned approximately parallel to the central axis of the manifold section. Consequently, no pipe curvature of the manifold pipe connectors is necessary. A very short installation space and very short connection routes up to the cylinder can be achieved. The main direction of collective flow of the collected manifold flows inside the manifold section runs fundamentally parallel to the central axis of the manifold section.

In this case, it can be advantageously envisaged that manifold pipes be provided, which are to be secured as a separate component between the respective manifold pipe connector and the flange plate. Greater distances between the manifold section or the respective manifold pipe connector and the cylinder can be bridged by means of the manifold pipes, particularly if the manifold pipe connectors are configured as rim holes.

It can be of particular importance for the present disclosure if the respective manifold pipe is configured cylindrically and/or the manifold pipes are configured identically in terms of their form and size. Since the manifold section having the integral manifold pipe connectors is already suitable for attaching to the cylinder head in terms of the architecture, the manifold pipes to be used can be very simply embodied to bridge a greater distance. With the exception of the distance, there is no need for any further adjustments to be made between the architecture of the manifold pipe connectors, on the one hand, and the cylinder, on the other hand.

It can be advantageous in connection with the configuration and arrangement according to the disclosure, if the respective half shell has a connection edge, by means of which the two half shells can be firmly bonded or positively connected to one another, wherein the separation plane T which is spanned by means of the respective connection edge is configured in a curved manner at least in sections. The curved configuration of the connection edge results in better weldability and simplifies the installation process on assembling the half shells. In addition, it makes it possible to save on material, resulting in less waste following forming.

It can furthermore be advantageous if the manifold section is located laterally offset from the catalyst housing section with respect to the central axis, wherein the central axis of the manifold section and the central axis of the catalyst housing section are aligned approximately parallel to one another. The main direction of flow is consequently deflected by 180°, starting from the main direction of collective flow, inside the manifold section. This results in improved mixing of the individual manifold flows. Additionally, an optimization of the installation space is therefore achieved.

In addition, it can be advantageous if a two-shell external housing is provided, which is located at a distance from the exhaust housing, wherein an insulating air gap is provided between the external housing and the exhaust housing. An air-gap insulated housing also has the aforementioned advantages.

It can furthermore be advantageous if the flange plate is secured in a gas-tight manner to the manifold pipe connectors or to the manifold pipes. The exhaust housing can be secured by means of the flange plate, if need be using a gasket, directly to the cylinder head of the internal combustion engine.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

Additional advantages and details of the disclosure are explained in the patent claims and in the description, and are illustrated in the figures, wherein:

FIG. 1 shows a schematic diagram of the exhaust housing in a view from above;

FIG. 2 shows a view from the front;

FIG. 3 shows a view in accordance with FIG. 1 as a further embodiment example;

FIG. 4 shows a schematic diagram of an exhaust system;

FIG. 5 shows a schematic diagram of a further embodiment example of the exhaust housing.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

An exhaust housing 1 shown in FIG. 1 has a two-shell configuration and has a first half shell 1 a and a second half shell 1 b. The two assembled half shells 1 a, 1 b or the exhaust housing 1 form a manifold section 1.1 as well as a catalyst housing section 1.2 and an exhaust pipe connector section 1.3 attached thereto, which are manufactured as a single piece with respect to the respective half shell 1 a, 1 b. The upper half shell 1 a, which is shown in accordance with FIG. 1, has, in the region of the manifold section 1.1, three manifold pipe connectors 1.4, 1.4′, 1.4″ which are configured inside the half shell 1 a as a rim hole.

The two half shells 1 a, 1 b have a connection edge 2 a, 2 b which in turn spans a separation plane T.

The manifold section 1.1 has a central axis 1.5 and the catalyst housing section 1.2 has a central axis 1.6, which are aligned coaxially to one another according to FIG. 1.

The three manifold pipe connectors 1.4, 1.4′, 1.4″ or the ends thereof span a connection plane A and a connection plane K, which are aligned parallel to the separation plane T in the embodiment example in accordance with FIG. 1. A flange plate 3 is secured to the three manifold pipe connectors 1.4, 1.4′, 1.4″, which flange plate is aligned parallel to the connection plane A. The exhaust housing 1 is connected to a cylinder 7 of an internal combustion engine, which is not shown in more detail, by means of the flange plate 3.

Since the manifold pipe connectors 1.4, 1.4′, 1.4″ are configured straight or free of curvature, the connection plane K is aligned parallel to the connection plane A.

It can be seen in the view in accordance with FIG. 2 that the separation plane T, spanned by means of the respective connection edge 2 a, 2 b, is configured in a curved manner. Both housing halves 1 a, 1 b can also be configured as a folding shell.

In the embodiment example in accordance with FIG. 3, a manifold pipe 4, 4″ is arranged on the respective manifold pipe connector 1.4, 1.4″. This serves to bridge the distance between the manifold section 1.1 and the cylinder 7. The manifold pipes 4, 4′, 4″ are each configured cylindrically and all have the same form. The connection plane K is therefore also arranged parallel to the connection plane A. An adjustment of the architecture of the manifold pipe connectors 1.4, 1.4′, 1.4″ to the architecture of the cylinder 7 or the cylinder outlet, which is not shown in further detail, is not necessary.

FIG. 4 shows an exhaust system 5 having an exhaust housing 1 in the embodiment according to one of FIGS. 1 to 3. In addition to the exhaust housing 1, the exhaust system 5 has an additional converter or catalyst 5.1 as well as an exhaust gas silencer 5.2, which are connected via an exhaust pipe 5.3. The exhaust housing 1 is hereby configured in an air-gap insulated form and additionally has an external housing 6 which, together with the internal housing, delimits an air gap 6.1.

In accordance with the embodiment example in FIG. 5, the manifold section 1.1 and the catalyst housing section 1.2 are connected to one another by means of a U-pipe section 1.7, so that both sections are arranged laterally offset from one another with respect to the respective central axis 1.1, 1.2. The collective flow running along the central axis 1.5 inside the manifold section 1.1 is deflected by means of the U-pipe section 1.7 by 180° and consequently aligned in accordance with the central axis 1.6 of the catalyst housing section 1.2.

A slight angular deviation of up to approx. 3° is possible between the two central axes 1.5, 1.6. This can be seen on the basis of the manifold section 1.1′ having the central axis 1.5′, which is shown with the dashed line.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 

1. A gas-carrying exhaust gas housing of an internal combustion engine comprising: a manifold section, having a central axis and multiple manifold pipe connectors, for securing on a flange plate or connecting to a cylinder of an internal combustion engine; a catalyst housing section having a central axis; and an exhaust pipe connector section provided downstream of the catalyst housing section, for connecting to an onward-conveying exhaust system, wherein, together with catalyst housing section and exhaust pipe connector section, the manifold section forms a two-shell exhaust housing having a first half shell and a second half shell, wherein the two half shells have a separation plane T running parallel to the central axis at least in sections, wherein the manifold section has multiple integral manifold pipe connectors which can be attached directly to a flange plate, wherein the respective manifold pipe connector is configured as a rim hole inside the first half shell.
 2. The gas-carrying exhaust gas housing according to claim 1, wherein the manifold section has a connection plane A for a flange plate, which is spanned by the manifold pipe connectors, wherein the manifold pipe connectors additionally span a connection plane K at the manifold section, and that the separation plane T is aligned parallel to the connection plane A and parallel to the connection plane K at least in the region of the manifold section.
 3. The gas-carrying exhaust gas housing according to claim 2, wherein the respective manifold pipe connector is configured straight or cylindrically and/or the manifold pipe connectors are configured identically in terms of their form and size.
 4. The gas-carrying exhaust gas housing according to claim 3, wherein manifold pipes are provided, which are to be secured as a separate component between the respective manifold pipe connector and the flange plate.
 5. The gas-carrying exhaust gas housing according to claim 4, wherein the respective manifold pipe is configured cylindrically and/or the manifold pipes are configured identically in terms of their form and size.
 6. The gas-carrying exhaust gas housing of claim 1, wherein the respective half shell has a connection edge, by means of which the two half shells can be firmly bonded or positively connected to one another, wherein the separation plane T which is spanned by means of the respective connection edge is configured in a curved manner at least in sections.
 7. The gas-carrying exhaust gas housing according to claim 1, wherein he manifold section is located laterally offset from the catalyst housing section with respect to the central axis, wherein the central axis of the manifold section and the central axis of the catalyst housing section are aligned approximately parallel to one another.
 8. The gas-carrying exhaust gas housing according to claim 1, wherein a two-shell external housing is provided, which is located at a distance from the exhaust housing, wherein an insulating air gap is provided between the external housing and the exhaust housing.
 9. The gas-carrying exhaust gas housing according to claim 1 having a flange plate, which is secured in a gas-tight manner to the manifold pipe connectors or to the manifold pipes.
 10. An exhaust system for a motor vehicle having a gas-carrying exhaust gas housing according to claim
 1. 